Equipment for the railway industry

14 rail transport l engineering EQUIPMENT FOR THE RAILWAY INDUSTRY ŽĎAS, a company based in Žďár nad Sázavou, manufactures high-quality and reliable devices for applications in the railway industry supported by cutting edge technology and significant references. The company mainly designs lines for the production of railway wheels and axles, and presses designed for the assembly and disassembly of railway wheelsets, always to individual customer requirements. ŽĎAS offers a complete line for forming railway wheels, which consists of a heating rotary hearth furnace, four hydraulic presses with unit drives, one rolling mill, handling equipment, marking equipment, and equipment for measuring the dimensions of the semi-finished wheels. Furthermore, the line is equipped with automatic tool change in hydraulic presses, including the preheating of tools. At the beginning of the production process, the cut input material blank is placed into a rotary hearth furnace. After heating, a manipulator places the material in the descaling device. When the scale has been removed, the manipulator moves the heated block to the CKZW 5600 upsetting press, where the block is centred into the press axis by means of a centring device. In the press, the block is compressed into the shape of a disk and another manipulator transfers it to the CKVZ 8000 forming press, where the centring and forming operation takes place. This is followed by the operation of punching the formed semi-product in the CKVD 1000 punching press. Then the final shape of the wheel is rolled in a rolling mill. In the CKVP 4000 dishing press, the wheel plate is then sized and dished. The finished wheel is marked in the stamping press and its shape is measured to see if it corresponds to specifications. The company is also able to provide the equipment with remote management, diagnostics, and data collection, which will provide input information for predictive maintenance and integration with Industry 4.0. The axles are forged from vacuum steel billets of the required quality. After being heated to forming temperature, the basic shape of the axle is forged on an integrated forging unit which consists of a CKNV 1000 push-down forging press, a QKK 1.5 forging manipulator, and a rotary lifting table. The basic axle design is generally forged using three die sizes, which allows for forging within the required specifications of ±1.5 mm, with a high degree of for- puter controlled heat treatment to achieve optimal mechanical properties. The deflection and shape deformation caused by the heat treatment is then adjusted on an RL 400 straightening press. Railway bogie wheels must have different properties in different places of their surface; they must be flexible and hard at the same time. The required hardness is achieved by reducing the elasticity, and therefore only the area of the wheel that rolls along the track is hardened. The CDRA hydraulic press is used for assembling railway wheelsets and cold pressing. The device also enables the pressing of components between the wheels and the pressing and inspection of the pressed joints. The press cylinder located in the fixed crossbeam uses a selected force over the pressed parts against the support crossbeam. The hydraulic wheel centring device is located on this, and the hydraulic axle centring device is located on the rear crossbeam. The control system provides press control and operation and fault diagnostics. The CDRM press is designed for cold pressing and the pressing of railway Railway bogie wheelsets assembled using the CDRA/CDRM hydraulic presses ging action. High mechanical properties of the axles are also achieved thanks to forged depth in the diameter transitions. After forging, the axle undergoes a com- Axle straightening on the RL 400 hydraulic straightening press wheelsets together. The device enables the assembly and disassembly of wheelsets for locomotives and railway cars with simultaneous recording of pressing force characteristics depending on the length of the pressed joint. After the pressing is complete, a report for archiving the complete process is printed. The press cylinder rests on a support beam which travels on wheels on two beams. Depending on the type of wheelset, the pressing force is absorbed by a support beam in predetermined locked positions. The advantages of both devices include precise control of the pressing force, simple operation, and high performance. p www.zdas.cz special 2020 T+T Technika a trh